Metal replacement triples lifetime of swimming pool lighting Showcase

A global lighting systems company chose Therma-Tech thermally conductive polymer to replace metal in the heat sink of LED lighting for swimming pools.

Showcase (real application example)

Akboru Elektrik, a global supplier of lighting systems for pools and gardens, selected Therma-Tech thermally conductive polymers from PolyOne to replace metal in the heat sink of LED lighting it developed for swimming pools. The transition from metal to the PolyOne material enabled Akboru Elektrik to increase the expected useful lifetime of the lights by 200%. Collaborating with PolyOne also supported the customer’s goals to improve its manufacturing and logistics efficiency, and reduce part weight.

“Our company always is on the lookout for innovative new materials to help us improve our manufacturing efficiency and the quality of our products,” explained Zafer Alkan, general manager of Akboru Elektrik. “PolyOne was able to formulate the material we wanted, and provided excellent support to our company during the design and manufacturing phases of the product’s introduction.”

Light Emitting Diode (LED) lights are much more efficient than incandescent bulbs at transforming electrical power into light, but LEDs still generate considerable heat. LEDs are sensitive to high temperatures, so heat sinks are often used to draw heat away from the lighting to extend its performance over time. Heat sinks typically are made of aluminum. However, aluminum parts are heavier and more costly to manufacture than specialty polymer solutions.

Akboru Elektrik, a global supplier of lighting systems for pools and gardens, selected Therma-Tech thermally conductive polymers from PolyOne to replace metal in the heat sink of LED lighting it developed for swimming pools. The transition from metal to the PolyOne material enabled Akboru Elektrik to increase the expected useful lifetime of the lights by 200%. Collaborating with PolyOne also supported the customer’s goals to improve its manufacturing and logistics efficiency, and reduce part weight.

“Our company always is on the lookout for innovative new materials to help us improve our manufacturing efficiency and the quality of our products,” explained Zafer Alkan, general manager of Akboru Elektrik. “PolyOne was able to formulate the material we wanted, and provided excellent support to our company during the design and manufacturing phases of the product’s introduction.”

Light Emitting Diode (LED) lights are much more efficient than incandescent bulbs at transforming electrical power into light, but LEDs still generate considerable heat. LEDs are sensitive to high temperatures, so heat sinks are often used to draw heat away from the lighting to extend its performance over time. Heat sinks typically are made of aluminum. However, aluminum parts are heavier and more costly to manufacture than specialty polymer solutions.

The Therma-Tech thermally conductive materials provided Akboru Elektrik the solution to oxidation problems on metal heat sinks. The manufacturer estimates the transition away from metal tripled the life of the lighting. In addition, the switch to these specialty polymers enabled Akboru Elektrik to reduce part weight by 50%. Daily production rates for this lighting were increased by up to 25%, and secondary operations, which were needed to complete the aluminum parts, were eliminated, reducing costs by more than 20% per unit.

“Our thermally conductive Therma-Tech polymers are rapidly becoming an industry standard for metal replacement in LED lighting systems, and we are pleased that Akboru Elektrik collaborated with us on this successful product launch,” said Holger Kronimus, vice president Europe and general manager, Specialty Engineered Materials, Europe at PolyOne. “We have tremendous experience supporting manufacturers with thermal and mold flow analysis, and helping them optimize their processing efficiency, making it possible for customers to achieve significant reductions in total part cost.”